Powered stapling device with manual retraction

ABSTRACT

A powered handle assembly includes a motor assembly, a rack, a spur gear, and a manual retract mechanism. The spur gear is movable from a position engaged with the motor assembly and the rack to a positioned disengaged from the motor assembly and engaged with the rack to facilitate manual retraction of the rack.

FIELD

This disclosure is directed to surgical devices and, more particularly,to powered surgical stapling devices.

BACKGROUND

Various types of surgical devices used to endoscopically treat tissueare known in the art, and are commonly used, for example, for closure oftissue or organs in transection, resection, and anastomoses procedures,for occlusion of organs in thoracic and abdominal procedures, and forelectrosurgically fusing or sealing tissue.

One example of such a surgical device is a surgical stapling device.Typically, surgical stapling devices include a tool assembly having ananvil assembly and a cartridge assembly, and a drive assembly.Typically, the drive assembly includes a flexible drive beam and a clampmember that is supported on a distal end of the drive beam. The driveassembly is movable to advance the clamp member through the toolassembly to approximate the cartridge and anvil assemblies and toadvance an actuation sled through the cartridge assembly to ejectstaples from the cartridge assembly.

Surgical stapling devices can be manually actuated devices in which aclinician squeezes a trigger to actuate the stapling device, or poweredstapling devices in which a clinician activates a motor within thestapling device to actuate the stapling device. Although poweredstapling devices require less force to operate, difficulties may arisewhen the device loses power or components of the device break. In suchinstances, the device can remain clamped about tissue preventing removalof the device from a patient.

A continuing need exists in the art for a powered stapling device thatincludes a drive assembly that can be manually retracted when power islost or when the device is not operational.

SUMMARY

A surgical device includes a powered handle assembly having a motorassembly, a rack, a spur gear, and a manual retract mechanism. The spurgear is movable from a position engaged with the motor assembly and therack to a positioned disengaged from the motor assembly and engaged withthe rack to facilitate manual retraction of the rack.

One aspect of the disclosure is directed to a powered handle assemblyfor a surgical device that includes a housing, a gear casing, a motorassembly, a rack, a rotating shaft, and a spur gear. The housing definesa cavity. The gear casing is supported within the cavity of the housingand defines a longitudinal channel, a first cavity, and a second cavitythat communicate with each other. The motor assembly includes an outputshaft and a drive gear that is secured to the output shaft. The motorassembly is secured to the gear casing, and the drive gear is positionedwithin the second cavity of the gear casing. The rack is received withinthe longitudinal channel of the gear casing and is movable betweenretracted and advanced positions. The rotating shaft extends through thefirst cavity of the gear casing. The spur gear is coupled to therotating shaft and is received within the first cavity of the gearcasing. The spur gear is movable within the first cavity from a firstposition in which the spur gear is engaged with the drive gear and therack to a second position in which the spur gear is disengaged from thedrive gear and engaged with the rack.

Other aspects of the disclosure are directed to a powered handleassembly for a surgical device that includes a housing, a motorassembly, a rack, a rotating shaft, and a spur gear. The housing definesa cavity. The motor assembly is supported within housing and includes anoutput shaft and a drive gear that is secured to the output shaft. Therack is supported within the housing and is movable longitudinallybetween retracted and advanced positions. The rotating shaft issupported within the housing. The spur gear is coupled to the rotatingshaft and received within the housing such that the spur gear is movablefrom a first position in which the spur gear is engaged with the drivegear and the rack to a second position in which the spur gear isdisengaged from the drive gear and engaged with the rack.

In aspects of the disclosure, the crank lever is coupled to the rotatingshaft and is movable to move the spur gear from the first position tothe second position.

In some aspects of the disclosure, a biasing member is engaged with thespur gear and urges the spur gear towards the first position.

In certain aspects of the disclosure, the rotating shaft includes afirst portion and a second portion, wherein the first portion isrotatably fixed to the spur gear and the second portion receives thecrank lever.

In aspects of the disclosure, the housing defines an opening andincludes a removable cover that is positioned over the opening such thatthe crank lever is accessible through the opening.

In some aspects of the disclosure, the crank lever is movable along thesecond portion of the rotating shaft from a first position in which therotating shaft can rotate independently of the crank lever to a secondposition in which the crank lever is rotatably fixed to the rotatingshaft.

In certain aspects of the disclosure, the crank lever includes a hubthat defines a through bore having a rectangular portion and the secondportion of the rotating shaft includes a rectangular portion that isreceived within the rectangular portion of the through bore when thecrank lever is in its second position.

In aspects of the disclosure, the handle assembly includes first andsecond C-clips, and the second portion of the rotating shaft definesspaced annular grooves that receive the first and second C-clips,respectively.

In some aspects of the disclosure, the spur gear is received about thesecond portion of the rotating shaft atop the first C-clip within thefirst cavity of the gear casing and the second C-clip is positionedexternally of the first cavity of the gear casing to secure the rotatingshaft to the gear casing.

Another aspect of the disclosure is directed to surgical stapling devicethat includes a powered handle assembly, an adapter assembly, and a toolassembly. The powered handle assembly includes a housing, a gear casing,a motor assembly, a rack, a rotating shaft, and a spur gear. The housingdefines a cavity. The gear casing is supported within the cavity of thehousing and defines a longitudinal channel, a first cavity, and a secondcavity that communicate with each other. The motor assembly includes anoutput shaft and a drive gear secured to the output shaft. The motorassembly is secured to the gear casing, and the drive gear is positionedwithin the second cavity of the gear casing. The rack is received withinthe longitudinal channel of the gear casing and is movable betweenretracted and advanced positions. The rotating shaft extends through thefirst cavity of the gear casing. The spur gear is coupled to therotating shaft and is received within the first cavity of the gearcasing. The spur gear is movable within the first cavity from a firstposition in which the spur gear is engaged with the drive gear and therack to a second position in which the spur gear is disengaged from thedrive gear and engaged with the rack. The adapter assembly has aproximal portion coupled to the handle assembly and a distal portion.The adapter assembly includes a firing rod that is coupled to the rackand is movable between retracted and advanced positions in response tomovement of the rack between its retracted and advanced positions. Thetool assembly is supported on the distal portion of the adapterassembly.

In aspects of the disclosure, the tool assembly includes an anvil and acartridge assembly that are movable between open and clamped positions.

In some aspects of the disclosure, the stapling device includes a driveassembly that is coupled to the firing rod and includes a working endhaving an I-beam configuration.

In certain aspects of the disclosure, the working end of the driveassembly is movable in relation to the anvil and the cartridge assemblyin response to movement of the firing rod between its retracted andadvanced positions.

Other aspects of the disclosure are directed to a powered handleassembly for a surgical device that includes a housing, a gear casing, amotor assembly, a drive screw, a drive nut, a connecting rod, and a spurgear. The housing defines a cavity. The gear casing is supported withinthe cavity of the housing and defines a channel. The motor assemblyincludes an output shaft and a drive gear secured to the output shaft.The motor assembly is secured to the gear casing, and the drive gear ispositioned within the cavity of the gear casing. The drive screw issupported within the housing and is rotatable in response to activationof the motor assembly. The drive nut is supported on and movable alongthe drive screw between retracted and advanced positions. The connectingrod is coupled to the drive nut. The spur gear is movable within thechannel of the gear casing from a first position in which the spur gearis engaged with the output shaft and the drive screw to a secondposition in which the spur gear is disengaged from the output shaft andengaged with the drive screw.

Other aspects of the disclosure are directed to a powered handleassembly for a surgical device that includes a housing, a motorassembly, a drive screw, a drive nut, a connecting rod, a spur gear, alocking clip, and a pawl assembly. The housing defines a cavity. Themotor assembly includes an output shaft and a drive gear secured to theoutput shaft. The motor assembly is positioned within the housing andthe drive gear is positioned within the cavity of the gear casing. Thedrive screw is supported within the housing and is rotatable in responseto activation of the motor assembly. The drive nut is supported on andmovable along the drive screw between retracted and advanced positions.The connecting rod is coupled to the drive nut. The spur gear is movablewithin the channel of the gear casing from a first position in which thespur gear is engaged with the output shaft and the drive screw to asecond position in which the spur gear is disengaged from the outputshaft and engaged with the drive screw. The locking clip is movable froma first position retaining the spur gear in its first position to asecond position allowing movement of the spur gear from its firstposition to its second position. The pawl assembly includes an annularbody portion and a ratcheting pawl coupled to the body portion.

In aspects of the disclosure, the handle assembly includes a biasingmember that is positioned to urge the spur gear to the second position.

In some aspects of the disclosure, the handle assembly includes alocking clip that is movable from a first position retaining the spurgear in its first position to a second position allowing movement of thespur gear from its first position to its second position.

In certain aspects of the disclosure, the handle assembly includes apawl assembly that includes a body portion and a ratcheting pawl coupledto the body portion.

In aspects of the disclosure, the gear casing defines a window and thebody portion of the pawl assembly is positioned about the gear casingadjacent the window such that the pawl assembly is movable from a firstposition in which the ratcheting pawl is spaced from the spur gear to asecond position in which the ratcheting pawl is engaged with the spurgear.

In some aspects of the disclosure, the connecting rod includes aproximal portion coupled to the drive nut and a distal portion coupledto a coupling member.

In certain aspects of the disclosure, the coupling member is adapted toengage a firing rod of the surgical device.

In aspects of the disclosure, the pawl assembly is coupled to thelocking clip such that movement of the pawl assembly from its firstposition to its second position moves the locking clip from its firstposition to its second position.

In some aspects of the disclosure, the gear casing defines spacedopenings, and the locking clip includes legs that are received withinthe openings.

Still other aspects of the disclosure are directed to a stapling deviceincluding a powered handle assembly, an adapter assembly, and a toolassembly. The powered handle assembly includes a housing, a gear casing,a motor assembly, a drive screw, a drive nut, a connecting rod, and aspur gear. the housing defines a cavity. The gear casing is supportedwithin the cavity of the housing and defines a channel. The motorassembly includes an output shaft and a drive gear secured to the outputshaft. The motor assembly is secured to the gear casing, and the drivegear is positioned within the cavity of the gear casing. The drive screwis supported within the housing and is rotatable in response toactivation of the motor assembly. The drive nut is supported on andmovable along the drive screw between retracted and advanced positions.The connecting rod is coupled to the drive nut. The spur gear is movablewithin the channel of the gear casing from a first position in which thespur gear is engaged with the output shaft and the drive screw to asecond position in which the spur gear is disengaged from the outputshaft and engaged with the drive screw. The adapter assembly has aproximal portion coupled to the handle assembly and a distal portion.The adapter assembly includes a firing rod that is coupled to the drivenut and is movable between retracted and advanced positions in responseto movement of the drive nut between its retracted and advancedpositions. The tool assembly is supported on the distal portion of theadapter assembly.

Other features of the disclosure will be appreciated from the followingdescription.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the disclosed staple cartridge are describedherein below with reference to the drawings, wherein:

FIG. 1 is a side perspective view of a first version of a staplingdevice according to aspects of the disclosure with the stapling devicein a non-articulated, unclamped position;

FIG. 2 is a side cutaway view of a handle assembly of the staplingdevice shown in FIG. 1 with a cover of the handle assembly removed;

FIG. 3 is a side perspective view of the handle assembly of the staplingdevice shown in FIG. 1 with a housing half-section removed;

FIG. 4 is an exploded side perspective view of internal components ofthe handle assembly shown in FIG. 3 ;

FIG. 5 is a side perspective view of a rotating shaft of the handleassembly shown in FIG. 3 ;

FIG. 6 is a perspective view of a crank lever of the handle assemblyshown in FIG. 3 ;

FIG. 7 is a cross-sectional view taken along section line 7-7 of FIG. 2;

FIG. 8 is a cross-sectional view taken through a portion of the handleassembly shown in FIG. 3 with the stapling device in an unclampedposition;

FIG. 9 is a cross-sectional view taken along section line 9-9 of FIG. 8;

FIG. 10 is a side perspective view of a reload assembly of the staplingdevice shown in FIG. 1 in the clamped and fired position;

FIG. 11 is a cross-sectional view taken along section line 11-11 of FIG.10 ;

FIG. 12 is a cross-sectional view through a portion of the handleassembly shown in FIG. 3 with the stapling device in the clamped andfired position;

FIG. 13 is a side perspective view of a portion of the handle assemblyshown in FIG. 3 as the stapling device is manually retracted from theclamped and fired position;

FIG. 14 is a cross-sectional view taken along section line 14-14 of FIG.13 ;

FIG. 15 is a cross-sectional view taken along section line 15-15 of FIG.14 ;

FIG. 16 is a side perspective view of the handle assembly of thestapling device shown in FIG. 1 with the cover of the handle assemblyremoved as the stapling device is manually retracted;

FIG. 17 is a cutaway, cross-sectional view taken through the handleassembly shown in FIG. 16 as the stapling device is manually retracted;

FIG. 18 is an alternate version of the handle assembly of the staplingdevice shown in FIG. 1 with a housing of the handle assembly shown inphantom;

FIG. 19 is an assembled view of the internal components of the handleassembly shown in FIG. 18 ;

FIG. 20 is an exploded side perspective view of internal components ofthe handle assembly shown in FIG. 19 ;

FIG. 21 is a side perspective view of a pawl assembly and locking clipof the handle assembly shown in FIG. 19 ;

FIG. 22 is a side perspective view from the proximal end of an interfacebetween a motor assembly and a drive assembly of the handle assemblyshown in FIG. 19 showing a manual retract mechanism with the lockingclip in the locked position;

FIG. 23 is a side perspective view from the distal end of the interfacebetween the motor assembly and the drive assembly of the handle assemblyshown in FIG. 20 with a gear casing removed showing the manual retractmechanism with the locking clip in the locked position;

FIG. 24 is a cross-sectional view taken along section line 24-24 of FIG.19 ;

FIG. 25 is a side cross-sectional view of the drive assembly of thehandle assembly of the stapling device shown in FIG. 24 in the firedposition;

FIG. 26 is a side perspective view from the proximal end of theinterface between the motor assembly and the drive assembly of thehandle assembly shown in FIG. 19 showing the manual retract mechanismwith the locking clip in the unlocked position;

FIG. 26A is a side cross-sectional view taken along section line 26A-26Aof FIG. 26 illustrating the manual retract mechanism in the unlockedposition;

FIG. 27 is a cross-sectional view taken along section line 27-27 of FIG.26 illustrating the manual retract mechanism as the manual retractmechanism is operated to move the locking clip from the locked positionto the unlocked position; and

FIG. 28 is a cross-sectional view taken along section line 27-27 of FIG.26 illustrating the manual retract mechanism as the manual retractmechanism is operated to retract the drive assembly.

DETAILED DESCRIPTION

The disclosed surgical device will now be described in detail withreference to the drawings in which like reference numerals designateidentical or corresponding elements in each of the several views.However, it is to be understood that the aspects of the disclosure aremerely exemplary of the disclosure and may be embodied in various forms.Well-known functions or constructions are not described in detail toavoid obscuring the disclosure in unnecessary detail. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limiting, but merely as a basis for the claims and asa representative basis for teaching one skilled in the art to variouslyemploy the disclosure in virtually any appropriately detailed structure.In addition, directional terms such as front, rear, upper, lower, top,bottom, and similar terms are used to assist in understanding thedescription and are not intended to limit the disclosure.

In this description, the term “proximal” is used generally to refer tothat portion of the device that is closer to a clinician, while the term“distal” is used generally to refer to that portion of the device thatis farther from the clinician. In addition, the term “endoscopic” isused generally to refer to endoscopic, laparoscopic, arthroscopic,and/or any other procedure conducted through a small diameter incisionor cannula. Further, the term “clinician” is used generally to refer tomedical personnel including doctors, nurses, surgeons, and supportpersonnel.

This disclosure is directed to a surgical device that includes a poweredhandle assembly having a motor assembly, a rack, a spur gear, and amanual retract mechanism. The spur gear is movable from a positionengaged with the motor assembly and the rack to a positioned disengagedfrom the motor assembly and engaged with the rack to facilitate manualretraction of the rack.

FIGS. 1 and 2 illustrate a surgical device shown generally as staplingdevice 10 which includes a handle assembly 12, an elongate body oradapter assembly 14, and a tool assembly 16. The handle assembly 12includes a housing 18 that forms a stationary handle portion 18 a, andarticulation lever 19, and actuation buttons 20. The adapter assembly 14defines a longitudinal axis “X” and includes a proximal portion 24 thatis coupled to the handle assembly 12, and a distal portion 26 thatsupports the tool assembly 16. The tool assembly 16 is secured to thedistal portion 26 of the adapter assembly 14 by a pivot member 28 thatdefines an axis “Y” that is transverse to the longitudinal axis “X”. Thearticulation lever 19 is operatively coupled to the tool assembly 16 viaan articulation linkage (not shown) such that manipulation of thearticulation lever 19 causes articulation of the tool assembly 16 aboutthe axis “Y” between an articulated position in which the tool assembly16 is aligned with the longitudinal axis “Y” and non-articulatedpositions in which a longitudinal axis of the tool assembly and thelongitudinal axis “X” define acute angles in response to manipulation ofthe articulation lever 19. The adapter assembly 14 is supported within arotation knob 30 that is rotatably coupled to a distal portion of thehandle assembly 12. The rotation knob 30 is manually rotatable about thelongitudinal axis “X” to rotate the adapter assembly 14 and the toolassembly 16 about the longitudinal axis “X”. The actuation buttons 20control operation of the different functions of the stapling device 10including clamping and firing of the stapling device 10.

In aspects of the disclosure, the tool assembly 16 forms part of areload assembly 32 that includes a proximal body portion 34 and the toolassembly 16. The proximal body portion 34 of the reload assembly 32forms an extension of the adapter assembly 14 and includes a proximalend that is adapted to be releasably coupled to a distal end of theadapter assembly 14 and a distal end that supports the tool assembly 16for articulation. In aspects of the disclosure, the tool assembly 16 canbe fixedly coupled to a distal portion of the adapter assembly 14.

In aspects of the disclosure, the housing 18 of the handle assembly 12is formed from half-sections that are coupled together such as bywelding of with screws to define a cavity 38 that receives internalcomponents of the handle assembly 12 which are described in furtherdetail below. The housing 18 defines an upper opening 40 that providesaccess to the internal components of the handle assembly 12. The upperopening 40 is enclosed by a cover 42 that is removably supported withinthe upper opening 40.

FIGS. 3 and 4 illustrate the internal components of the handle assembly12 which include a gear casing 44, a motor assembly 46, a rack 48, afiring rod 50, a manual retract mechanism 52 and intermediate spur gear54, and a drive gear 56. The gear casing 44 is secured within the cavity38 of the housing 18 using screws or the like and defines a first cavity60 and a second cavity 62 that intersect with each other and alongitudinally extending channel 64. The first cavity 60 of the gearcasing 44 receives the drive gear 56 and the second cavity 62 of thegear casing 44 receives the intermediate spur gear 54. The drive gear 56and the intermediate spur gear each include gear teeth that mesh suchthat rotation of the drive gear 56 within the first cavity 60 causescorresponding rotation of the intermediate spur gear 54 within thesecond cavity 62. The rack 48 is received within the channel 64 of thegear casing 44 and includes gear teeth that mesh with the gear teeth ofthe intermediate spur gear 54. When the drive gear 56 is rotated torotate the intermediate spur gear 54, engagement between theintermediate spur gear 56 and the rack 48 causes the rack 48 to movelongitudinally through the channel 64 in the gear casing 44.

The motor assembly 46 includes an output shaft 70 (FIG. 4 ) that issecured to the drive gear 56 and can be activated via the actuationbuttons 20 (FIG. 1 ) to rotate the drive gear 56. In aspects of thedisclosure, the motor assembly 46 is positioned within a portion of thecavity 38 of the housing 18 defined by the stationary handle portion 18a. The motor assembly 46 includes a mounting bracket 72 that is securedto the gear casing 44 with screws 74 such that the drive gear 56 isreceived within the second cavity 62 of the gear casing 44.

FIGS. 4-6 illustrate the manual retract mechanism 52 which includes arotating shaft 78, a crank lever 80, and a grip member 82. The cranklever 80 includes a central hub portion 84 that defines a through bore86 that receives the rotating shaft 78. The through bore 86 includes acylindrical portion 86 a and a rectangular portion 86 b. The crank lever80 also includes a lever portion 88 that defines a slot 90 and forms aclevis 92. The grip member 82 is supported within the clevis 92 by apivot member 94 and is pivotable between a first position located withinthe slot 90 and a second position extending orthogonally from the leverportion 88.

The rotating shaft 78 includes a head portion 96 and a shaft portion 98that extends downwardly from the head portion 96 as viewed in FIG. 4through the through bore 86 in the crank lever 80. The shaft portion 98includes a first rectangular portion 100, a cylindrical portion 102, anda second rectangular portion 104. The second rectangular portion 104includes spaced annular grooves 106 and 108 that receive C-clips 110 and112, respectively. The intermediate spur gear 54 is received about thesecond rectangular portion 104 of the rotating shaft 78 atop the C-clip112 within the first cavity 60 of the gear casing 44. The C-clip 112 ispositioned externally of the first cavity 60 and secures the rotatingshaft 78 to the gear casing 44. Although the rotating shaft 78 is shownto have first and second rectangular portions, it is envisioned thatother shaft configurations are envisioned.

The gear casing 44 defines first and second openings 114 and 116 thatcommunicate with upper and lower ends of the first cavity 60 of the gearcasing 44. The cylindrical portion 102 of the rotating shaft 78 isreceived within the first opening 114 of the gear casing 44 and thesecond rectangular portion 104 of the rotating shaft 78 extends throughthe second opening 116 of the gear casing 44. The C-clip 110 is securedto the lower end of the second rectangular portion 104 of the rotatingshaft 78 adjacent a lower surface of the gear casing 44 and the C-clip112 is secured to the second rectangular portion 104 of the rotatingshaft 78 within the first cavity 60 of the gear casing 44. The C-clips110 and 112 secure the intermediate spur gear 54 to the rotating shaft78 and secure the rotating shaft 78 to the gear casing 44. The secondrectangular portion 104 of the rotating shaft 78 is received within arectangular bore in the intermediate spur gear 54 to rotatably fix theintermediate spur gear 54 to the rotating shaft 78.

The intermediate spur gear 54 is received within the first cavity 60 ofthe gear casing 44 and is movable within the first cavity between afirst or lower position and a second or upper position. In the lowerposition (FIG. 8 ), the teeth of the intermediate spur gear 54simultaneously engage the teeth of the rack 48 and the teeth of thedrive gear 56. In the upper position, the teeth of the intermediate spurgear 54 engage only the teeth of the rack 48.

The manual retract mechanism 52 includes a biasing member 120 that ispositioned between an upper surface of the intermediate spur gear 54 andthe inner surface of the gear casing 44. The biasing member 120 urgesthe intermediate spur gear 54 towards its lower position in which theintermediate spur gear 54 is engaged with both the drive gear 56 and therack 48. In some aspects of the disclosure, a washer 122 is positionedbetween an upper surface of the biasing member 120 and the inner surfaceof the gear casing 44. In some aspects of the disclosure, the biasingmember 120 includes a coil spring. It is envisioned that other types ofbiasing members could be incorporated into the stapling device 10 (FIG.1 ).

The rack 44 includes a distal portion that is coupled to the firing rod50, In aspects of the disclosure, the proximal portion of the firing rod50 is formed with a head 124 that has a diameter that is larger than abody of the firing rod 50 and the distal portion of the rack 48 definesa slot 128. The head 124 of the firing rod 50 is received within theslot 128 of the rack 48 to couple the firing rod 50 to the rack 48 suchthat longitudinal movement of the rack 48 causes longitudinal movementof the firing rod 50. The coupling of the head 124 and the slot 128allows the firing rod 50 to rotate in relation to the rack 48.

In some aspects of the disclosure, the manual retract mechanism 52includes a base member 130 that defines a circular bore 132. The basemember 130 is secured to an upper surface of the gear casing 44 and thehub portion 84 of the crank lever 80 is aligned within the circular bore132. The crank lever 80 is movable from a lowered position to a raisedposition. In the lowered position, the hub portion 84 of the crank lever80 is received within the circular bore 132 and in the raised position,the hub portion 84 of the crank lever 80 is positioned above thecircular bore 132 of the base member 130.

The head 96 of the rotating shaft 78 of the manual retract mechanism 52is received within the bore 86 of the crank lever 80. When the cranklever 80 is in its lowered position, the cylindrical portion 102 of therotating shaft 78 is received within the rectangular portion 86 b (FIG.6 ) of the through bore 86 of the crank lever 80. In this position, therotating shaft 78 can rotate within the through bore 86 of the cranklever 80 without causing rotation of the crank lever 80. When the cranklever 80 is moved to its raised position, the first rectangular portion100 of the rotating shaft 78 is received within the rectangular portion86 b of the through bore 86 of the crank lever 80, In this position,rotation of the crank lever 80 causes corresponding rotation of therotating shaft 78, and thus, rotation of the intermediate spur gear 54.The head 96 of the rotating shaft 78 has a diameter that is larger thanthe width of the rectangular portion 86 b of the through bore 86 of thecrank lever 80. Thus, movement of the crank lever 80 to its raisedposition causes the rotating shaft 78 to its upper position in which theteeth of the intermediate spur gear 54 are only engaged with the teethof the rack 48.

The handle assembly 12 (FIG. 1 ) also includes one or more batteries 140which are received within the cavity 38 of the housing 18 of the handleassembly 12. The batteries 140 provide power to the motor assembly 46via the actuation switches and control circuitry (not shown), e.g., aprinted circuit board and one or more controllers, within the handleassembly 12 to control firing of the stapling device 10.

FIGS. 7-9 illustrate the handle assembly 12 of the stapling device 10(FIG. 1 ) with the stapling device in an unclamped position prior tofiring of the stapling device. In this position, the rack 48 is in aretracted position within the channel 64 of the gear casing 44 and theintermediate spur gear 54 is in its lowered position and is engaged withthe rack 48 and the drive gear 56.

FIGS. 10 and 11 illustrate the reload assembly 32 when the staplingdevice 10 is in a fired position. As described above, the reloadassembly 32 includes the tool assembly 16 and the proximal body portion34. In aspects of the disclosure, the tool assembly 16 includes an anvilassembly 150 and a cartridge assembly 152. The cartridge assembly 152includes a staple cartridge 154 that supports a plurality of staples andpushers (not shown), and an actuation sled 156. The proximal bodyportion 32 includes a drive assembly 158 that includes a flexible beam160 and a working end 162. The working end 162 of the drive assembly 158has an I-beam configuration and is secured to a distal end portion ofthe flexible beam 160. The flexible beam 160 has a proximal end portionthat is releasably coupled to a distal portion of the firing rod 50.When the firing rod 50 is moved from a retracted position to an advancedposition, the drive assembly 158 moves from a retracted position to anadvanced position to move the working end 162 of the drive assembly 158through the tool assembly 16 to advance the actuation sled 156 throughthe tool assembly 16. As the actuation sled 156 moves through the toolassembly 16, the actuation sled 156 engages the pushers (not shown) toeject staples (not shown) from the staple cartridge 154 into the anvilassembly 150. In the fired position, the working end 162 of the driveassembly 158 and the actuation sled 156 are in their advanced positionswithin the tool assembly and the tool assembly is in the clampedposition clamped about tissue (not shown). For a more detaileddescription of the operation of the drive assembly 158 and itsinteraction with the tool assembly, see U.S. Pat. No. 8,132,706.

FIG. 12 illustrates the handle assembly 12 of the stapling device 10(FIG. 1 ) as the stapling device 10 is fired. When the stapling device10 is fired, the intermediate spur gear 54 (FIG. 8 ) is engaged with therack 48 and with the drive gear 56. When the motor assembly 46 isactivated, the drive gear 56 rotates the intermediate spur gear 54 toadvance the rack 48 in the direction indicated by arrows “A”. The rack48 is coupled to the firing rod 50 such that advancement of the firingrod 50 advancement of the rack 48 causes advancement of the firing rod50 in the direction of arrows “A” to advance the drive assembly 158(FIG. 11 ) within the tool assembly 16.

FIGS. 13-15 illustrate the manual retract mechanism 52 as it is readiedfor use. When the stapling device 10 loses power or gets damaged suchthat the motor assembly 46 cannot retract the drive assembly 158 torelease tissue clamped between the anvil and cartridge assemblies 150and 152 (FIG. 11 ), the manual retract mechanism 52 can be operated toretract the drive assembly 158 (FIG. 11 ). In order to access the manualretract mechanism 52, the cover 42 (FIG. 2 ) must be removed to uncoverthe upper opening 40 in the housing 18 of the handle assembly 12. Oncethe cover is removed, the crank lever 80 is pulled upwardly in thedirection of arrow “C” in FIG. 13 to move the crank lever 80 from itslowered position to its raised position. As the crank lever 80 is movedtowards its raised position, the first rectangular portion 100 of therotating shaft 78 is received in the rectangular portion 86 b of thethrough bore 86 in the crank lever 80. Once the first rectangularportion 100 of the rotating shaft 78 is received in the rectangularportion 86 b of the through bore 86 in the crank lever 80, continuedmovement of the crank lever 80 in the direction of arrow “C” will liftthe rotating shaft 78 and the intermediate spur gear 54 in the directionof arrows “D” in FIG. 14 to their upper positions compressing thebiasing member 120. In the upper position, the intermediate spur gear 54is disengaged from the drive gear 56 and is engaged only with the rack48. Once the crank lever 80 is in its raised position, the grip member82 can be pivoted about the pivot member 94 to an operational position.

FIGS. 16 and 17 illustrate the manual retract mechanism 52 as it isoperated to retract the firing rod 50. Once the crank lever 80 is movedto its raised position, the crank lever 80 can be rotated in thedirection indicated by arrow “E” in FIG. in FIG. 16 to rotate therotating shaft 78 and the intermediate spur gear 54 in the directionindicted by arrow “F” in FIG. 17 to retract the rack 48. Morespecifically, when the crank lever 80 is rotated, receipt of the firstrectangular portion 100 of the rotating shaft 78 in the rectangularportion 86 b of the through bore 86 of the crank lever 80 rotatablyfixes the crank lever 80 to the rotating shaft 78. Thus, when the cranklever 80 rotates, the rotating shaft also rotates. The intermediate spurgear 54 is rotatably fixed to the rotating shaft 78 via receipt of thesecond rectangular portion 104 of the rotating shaft 78 in therectangular bore 54 a of the intermediate spur gear 54 such thatrotation of the rotating shaft 78 causes rotation of the intermediatespur gear 54. In its upper position, the intermediate spur gear 54 isonly engaged with the rack 48, and as such, rotation of the intermediatespur gear 54 causes retract of the rack 48.

FIGS. 19-28 illustrate an alternate version of the handle assembly 12(FIG. 18 ) of the stapling device 10 shown generally as handle assembly312. The handle assembly 312 includes a housing 314 that issubstantially similar to housing 18 (FIG. 1 ) of stapling device 10 andwill not be described in further detail herein. The housing 314 definesa cavity 316 that receives the internal components of the handleassembly 312.

FIGS. 18-20 illustrate the internal components of the handle assembly312 which includes a motor assembly 318, a drive assembly 320, and amanual retract mechanism 322. The motor assembly 318 is supported withinthe cavity 316 (FIG. 18 ) of the housing 314 and includes an outputshaft 324 that has a flat surface 324 a. In some aspects of thedisclosure, the output shaft 324 has a D-shaped configuration althoughother configurations are envisioned.

The drive assembly 320 is coupled to the output shaft 324 of the motorassembly 318 and includes a one-way spur gear 328, a drive screw 330, adrive nut 332, connecting rods 334, a coupling member 336, a guide tube338, and a gear casing 340. The gear casing 340 includes a mountingflange 342 and a cylindrical body 344. The mounting flange 342 of thegear casing 340 defines bores 346 that receive screws 348. The screws348 are received in threaded bores 350 formed in a distal face of themotor assembly 318 to secure the gear casing 340 to the motor assembly318. The cylindrical body 344 of the gear casing 340 defines a cavity352 and a window 354 that communicates with the cavity 352. Thecylindrical body 344 of the gear casing 340 defines two openings 356(only one is shown) and two cutouts 358. One of the openings 356 and oneof the cutouts 358 is positioned on each side of the window 354 invertical alignment. The cavity 352 of the cylindrical body 344 of thegear casing 340 receives the one-way spur gear 328. The distal portionof the cylindrical body 344 of the gear casing 340 supports a bearing359.

The one-way spur gear 328 defines a central through bore 360 thatreceives a bearing 362. In aspects of the disclosure, the centralthrough bore 360 and the bearing 362 have corresponding non-circularconfigurations, e.g., D-shaped configurations, such that the bearing 362is slidably received within the central through bore 360 of the one-wayspur gear 328. The corresponding configurations of the one-way spur gear328 and the bearing 362 rotatably fix the components to each other. Thebearing 362 also defines a central through bore 364 that has anon-circular configuration.

The drive screw 330 includes a threaded outer surface 366, a proximalextension 368, and a distal extension 370. The proximal extension 368 ofthe drive screw 330 extends through the bearing 359 within the gearcasing 340 and is received and secured within the central through bore364 of the bearing 364. The distal extension 370 of the drive screw 330is received within a bearing 372 that is supported within the housing314 (FIG. 18 ) to rotatably support the drive screw 330 within thehousing 314.

When the motor assembly 318 is activated to rotate the output shaft 324,rotation of the output shaft 324, when engaged with the one-way spurgear 328, causes corresponding rotation of the one-way spur gear 328. Asdescribed above, the one-way spur gear 328 is rotatably fixed to thebearing 362 which is secured to and rotatably fixed to the drive screw330. As such, rotation of the one-way spur gear 328 causes correspondingrotation of the drive screw 330.

The drive nut 332 includes a threaded bore 374 that receives and isthreadably engaged with the threaded outer surface 366 of the drivescrew 330. The drive nut 332 is coupled to a proximal portion of theconnecting rods 334. In aspects of the disclosure, the drive nut 332includes protrusions 378 that are received within openings 380 formed inthe proximal portions of the connecting rods 334 to connect the drivenut 332 to the connecting rods 334. The connecting rods 334 extenddistally from the drive nut 332 and include distal portions that areconnected to the coupling member 336. In aspects of the disclosure, thecoupling member 336 includes protrusions 384 that are received withinopenings 386 formed in the distal portions of the connecting rods 334 toconnect the coupling member 336 to the connecting rods 334. The drivenut 332 and the connecting rods 334 are received within the guide tube338.

When the drive screw 330 is rotated, engagement between the outerthreaded surface 366 of the drive screw 330 and the inner threaded bore374 of the drive nut 332 causes the drive nut 332 to translatelongitudinally along the drive screw 330 within the guide tube 338. Thedrive nut 332 is connected to the connecting rods 334 such thatlongitudinal translation of the drive nut 332 along the drive screw 330causes the connecting rods 334 to move longitudinally within the guidetube to advance to coupling member 336.

The coupling member 336 is coupled to a firing rod 382 such thatlongitudinal movement of the coupling member 336 causes longitudinalmovement of the firing rod 382. In aspects of the disclosure, the firingrod 382 includes a head portion 384 and an elongate body 386. The headportion 384 has a diameter that is greater than a diameter of theelongate body 386. The coupling member 336 defines a slot 390 that has awidth that is greater than the diameter of the elongate body 386 butless than the diameter of the head portion 384. The elongate body 386 ofthe firing rod 382 is received through the slot 390 in the couplingmember 336 to axially fix the firing rod 382 to the coupling member 336while allowing relative rotation of the firing rod 382 and the couplingmember 336.

The one-way spur gear 328 is movably positioned within the cavity 352 ofthe cylindrical body 344 of the gear casing 340 between a retractedposition (FIG. 24 ) and an advanced position (FIG. 26A). In the advancedposition, the one-way spur gear is engaged with the proximal extension368 of the drive screw 330 and the output shaft 324 of the motorassembly 318 such that rotation of the output shaft 324 of the motorassembly 324 causes rotation of the drive screw 330. In the advancedposition, the one-way spur gear 328 is disengaged from the output shaft324 of the motor assembly 318 but still engaged with the drive screw330. A biasing member 396, e.g., a coil spring, is positioned betweenthe distal surface of the motor assembly 318 and a proximal surface ofthe one-way spur gear 328 to urge the one-way spur gear 328 towards theadvanced position. In aspects of the disclosure, the proximal surface ofthe one-way spur gear 328 defines a recess 328 a (FIG. 26A) thatreceives the biasing member 396.

FIGS. 20 and 21 illustrate the manual retract mechanism 322 includes apawl assembly 410 and a locking clip 412. The pawl assembly 410 includesa handle 414 and a body portion 416. In aspects of the disclosure, thebody portion has an oval or annular configuration and supports aratcheting pawl 418 that is pivotably secured to an upper portion of thebody portion 416 by a pivot member 420. The ratcheting pawl 418 extendsdownwardly into a circular opening defined by the body portion 416. Thebody portion 416 is received about the gear casing 340 with theratcheting pawl 418 positioned over the window 354 in the gear casing340 above the one-way spur gear 328. A lower portion of the body portion416 defines a circular slot 422.

The locking clip 412 has a rectangular shape and includes a base portion426 and spaced legs 428 that extend upwardly from the base portion 426.Each of the legs 428 of the locking clip 412 includes a stepped innersurface 430 that includes a first surface 430 a and a second surface 430b. The first surfaces 430 a of the legs 428 define a first width X₁ andthe second surfaces 430 b define a second width X₂ that is greater thanthe first width X₂. Each of the legs 428 is received through one of theopenings 356 and cutouts 358 of the gear casing 340 such that thestepped inner surfaces 430 of the legs 428 of the locking clip 412 arepositioned within the cavity 352 of the gear casing 340. The lockingclip 322 is movable from a first position (FIG. 23 ) in which the firstsurfaces 430 a of the legs 428 of the locking clip 322 are aligned withthe one-way spur gear 328 and a second position in which the secondsurfaces 430 b of the legs 428 of the locking clip 322 are spaced fromthe one-way spur gear 328. The width X₁ between the first surfaces 430 aof the legs 428 of the locking clip 322 is such to prevent movement ofthe one-way spur gear 322 to its advanced position, whereas the width X₂between the second surfaces 430 b of the legs 428 of the locking clip322 allows movement of the one-way spur gear 322 to the advancedposition.

The base portion 426 of the locking clip 322 includes a protrusion 434that is received within the circular slot 422 in the body portion 416 ofthe pawl assembly 410. Receipt of the protrusion 434 couples the pawlassembly 410 to the locking clip 322 to retain the pawl assembly 410 ina stable position about the gear casing 340. In aspects of thedisclosure, the protrusion 434 has an enlarged head and the circularslot includes overhanging ledges that retain the enlarged head of theprotrusion 434 within the circular slot 422. The protrusion 434 isconfigured to slide within the circular slot 422 as described in furtherdetail below.

FIGS. 22-24 illustrate the handle assembly 12 (FIG. 18 ) in a pre-firedposition with the pawl assembly 322 positioned about the gear casing 340and the ratcheting pawl 418 positioned above the window 354 in the gearcasing 340. When the handle assembly 12 is assembled, the one-way spurgear 328 is pressed proximally towards the motor assembly 318 tocompress the biasing member 396 and position the one-way spur gear 328in its retracted position. After the one-way spur gear 328 is in itsretracted position, the legs 428 of the locking clip 412 are insertedfrom a side of the gear casing 340 opposite to the ratcheting pawl 418into the openings 356 and cutouts 358 formed in the gear casing 340 toits first position. In the first position of the locking clip 412, thefirst surfaces 430 a of the legs 428 of the locking clip 412 engage adistal face of the one-way spur gear 328 to retain the one-way spur gear328 in its retracted position against the urging of the biasing member396. In its retracted position, the one-way spur gear 328 is engagedwith both the output shaft 324 of the motor assembly 318 and the one-wayspur gear 328. When the locking clip 412 is in its first position, theprotrusion 434 on the locking clip 412 is pressed into the circular slot422 on the body portion 416 of the pawl assembly 322 to couple the pawlassembly 322 to the locking clip 412 (FIG. 24 ).

In the pre-fired position of the handle assembly 12 (FIG. 18 ), thedrive nut 322 is positioned near the proximal end of the drive screw 330and the coupling member 336 is positioned adjacent the distal end of theguide tube 338 such that the connecting rods 334 are in retractedpositions and the firing rod 382 is in its retracted position.

FIG. 25 illustrates the handle assembly 12 (FIG. 1 ) in a firedposition. When the stapling device 10 (FIG. 1 ) is fired by pressing theactuation buttons 20 (FIG. 1 ), the motor assembly 318 is activated torotate the output shaft 324. Rotation of the output shaft 324 causescorresponding rotation of the one-way spur gear 328 and the drive screw330 to advance the drive nut 322 along the drive screw 330 in thedirection of arrow “J”. As the drive screw 330 advances the drive nut322, the drive nut 322 advances the connecting rods 334 to advance thefiring rod 382 in the direction of arrow “K” and actuate the toolassembly 16 (FIG. 1 ) as described above regarding stapling device 10(FIG. 1 ).

When the tool assembly 16 is in the clamped and fired position (FIG. 11) and the powered stapling device 10 (FIG. 1 ) becomes inoperable andcannot be unclamped using the motor assembly 318, the manual retractmechanism 322 allows the tool assembly to be manually unclamped. FIGS.26-28 illustrate operation of the manual retract mechanism 322. In orderto operate the manual retract mechanism 322, the pawl assembly 322 ispressed downwardly in the direction of arrows “L” in FIGS. 26-27 . Whenthe pawl assembly 322 is pressed downwardly, the locking clip 412, whichis coupled to the pawl assembly 322 by the protrusion 434, is moved fromits first position to its second position. In its second position, thelocking clip 412 disengages from the one-way spur gear 328 such that thebiasing member 396 moves the one-way spur gear 328 from its retractedposition to its advanced position. In its advanced position, the one-wayspur gear 328 is disengaged from the output shaft 324 of the motorassembly 318. When the pawl assembly 322 is pressed downwardly, theratcheting pawl 418 moves through the window 354 of the gear housing 340into engagement with the one-way spur gear 328.

After the one-way spur gear 328 is in its advanced position, the handle414 of the pawl assembly 322 can be rotated in the direction of arrow“M” in FIG. 28 to rotate the one-way spur gear 328 and the drive screw330 to retract the firing rod 382. As the pawl assembly 322 is rotated,the protrusion 434 moves within the circular slot 422 of the pawlassembly 322.

Persons skilled in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting exemplary embodiments. It is envisioned thatthe elements and features illustrated or described in connection withone exemplary embodiment may be combined with the elements and featuresof another without departing from the scope of the disclosure. As well,one skilled in the art will appreciate further features and advantagesof the disclosure based on the above-described embodiments. Accordingly,the disclosure is not to be limited by what has been particularly shownand described, except as indicated by the appended claims.

What is claimed is:
 1. A powered handle assembly for a surgical devicecomprising: a housing defining a cavity; a gear casing supported withinthe cavity of the housing, the gear casing defining a longitudinalchannel, a first cavity, and a second cavity that communicate with eachother; a motor assembly including an output shaft and a drive gearsecured to the output shaft, the motor assembly secured to the gearcasing, and the drive gear being positioned within the second cavity ofthe gear casing; a rack received within the longitudinal channel of thegear casing and movable between retracted and advanced positions; arotating shaft extending through the first cavity of the gear casing;and a spur gear coupled to the rotating shaft and received within thefirst cavity of the gear casing, the spur gear movable within the firstcavity from a first position in which the spur gear is engaged with thedrive gear and the rack to a second position in which the spur gear isdisengaged from the drive gear and engaged with the rack.
 2. The poweredhandle of claim 1, further including a crank lever coupled to therotating shaft, the crank lever movable to move the spur gear from firstposition to the second position.
 3. The powered handle of claim 2,further including a biasing member engaged with the spur gear, thebiasing member urging the spur gear towards the first position.
 4. Thepowered handle of claim 3, wherein the rotating shaft includes a firstportion and a second portion, the first portion rotatably fixed to thespur gear, and the second portion receiving the crank lever.
 5. Thepowered handle of claim 4, wherein the housing defines an opening andincludes a removable cover positioned over the opening, the crank leverbeing accessible through the opening.
 6. The powered handle of claim 5,wherein the crank lever is movable along the second portion of therotating shaft from a first position in which the rotating shaft canrotate independently of the crank lever to a second position in whichthe crank lever is rotatably fixed to the rotating shaft.
 7. The poweredhandle of claim 6, wherein the crank lever includes a hub that defines athrough bore having a rectangular portion and the second portion of therotating shaft includes a rectangular portion that is received withinthe rectangular portion of the through bore when the crank lever is inits second position.
 8. The powered handle of claim 4, further includingfirst and second C-clips, the second portion of the rotating shaftdefining spaced annular grooves that receive the first and secondC-clips, respectively.
 9. The powered handle of claim 8, wherein thespur gear is received about the second portion of the rotating shaftatop the first C-clip within the first cavity of the gear casing 44 andthe second C-clip is positioned externally of the first cavity of thegear casing and securing the rotating shaft to the gear casing.
 10. Asurgical stapling device comprising: a powered handle assemblyincluding: a housing defining a cavity; a gear casing supported withinthe cavity of the housing, the gear casing defining a longitudinalchannel, a first cavity, and a second cavity that communicate with eachother; a motor assembly including an output shaft and a drive gearsecured to the output shaft, the motor assembly secured to the gearcasing, and the drive gear being positioned within the second cavity ofthe gear casing; a rack received within the longitudinal channel of thegear casing and movable between retracted and advanced positions; arotating shaft extending through the first cavity of the gear casing;and a spur gear coupled to the rotating shaft and received within thefirst cavity of the gear casing, the spur gear movable within the firstcavity from a first position in which the spur gear is engaged with thedrive gear and the rack to a second position in which the spur gear isdisengaged from the drive gear and engaged with the rack; an adapterassembly having a proximal portion and a distal portion, the proximalportion coupled to the handle assembly, the adapter assembly including afiring rod that is coupled to the rack and movable between retracted andadvanced positions in response to movement of the rack between itsretracted and advanced positions; and a tool assembly supported on thedistal portion of the adapter assembly.
 11. The stapling device of claim10, wherein the handle assembly further includes a crank lever coupledto the rotating shaft, the crank lever movable to move the spur gearfrom first position to the second position.
 12. The stapling device ofclaim 11, wherein the handle assembly further includes a biasing memberengaged with the spur gear, the biasing member urging the spur geartowards the first position.
 13. The stapling device of claim 12, whereinthe handle assembly further includes a first portion and a secondportion, the first portion rotatably fixed to the spur gear, and thesecond portion receiving the crank lever.
 14. The stapling device ofclaim 13, wherein the housing of the handle assembly defines an openingand includes a removable cover positioned over the opening, the cranklever being accessible through the opening.
 15. The stapling device ofclaim 14, wherein the crank lever of the handle assembly is movablealong the second portion of the rotating shaft from a first position inwhich the rotating shaft can rotate independently of the crank lever toa second position in which the crank lever is rotatably fixed to therotating shaft.
 16. The stapling device of claim 15, wherein the cranklever of the handle assembly includes a hub that defines a through borehaving a rectangular portion and the second portion of the rotatingshaft includes a rectangular portion that is received within therectangular portion of the through bore when the crank lever is in itssecond position.
 17. The stapling device of claim 13, wherein the handleassembly further includes first and second C-clips, the second portionof the rotating shaft defining spaced annular grooves that receive thefirst and second C-clips, respectively, the spur gear being receivedabout the second portion of the rotating shaft atop the first C-clipwithin the first cavity of the gear casing and the second C-clip beingpositioned externally of the first cavity of the gear casing andsecuring the rotating shaft to the gear casing.
 18. The stapling deviceof claim 10, wherein the tool assembly includes an anvil and a cartridgeassembly, the anvil and the cartridge assembly cartridge assembly beingmovable between open and clamped positions.
 19. The stapling device ofclaim 18, further including a drive assembly coupled to the firing rod,the drive assembly including a working end having an I-beamconfiguration, the working end of the drive assembly movable in relationto the anvil and the cartridge assembly in response to movement of thefiring rod between its retracted and advanced positions.
 20. A poweredhandle assembly for a surgical device comprising: a housing defining acavity; a motor assembly including an output shaft and a drive gearsecured to the output shaft, the motor assembly supported withinhousing; a drive screw supported within the housing; a rotating shaftsupported within the housing; and a spur gear coupled to the rotatingshaft and received within the housing, the spur gear movable from afirst position in which the spur gear is engaged with the drive gear andthe rack to a second position in which the spur gear is disengaged fromthe drive gear and engaged with the rack.